Stator Tile Fastening for Impact Crusher Wear Parts
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Solution Overview
Problem
Impact crushers used for separating composite materials face significant wear and tear, leading to safety risks and complex maintenance due to the current methods of attaching replaceable tiles, which are either loosely held by gravity or require difficult internal screw connections.
Innovation Solution
Cast metal tiles with threaded holes are used, secured by fastening bolts passing through bushings in the stator's outer jacket wall, allowing for external fastening and improved safety, along with support strips and mats for enhanced stability and vibration damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If tiles are suspended by gravity in an annular groove, then tiles are easy to replace, but safety risk increases due to potential detachment under high impact forces
Solution Approach 1:
The tile fastening system is segmented into multiple independent retention points: the annular groove provides gravitational retention while threaded holes with fastening bolts provide mechanical anchoring. This segmentation allows the tile to be secured by multiple mechanisms simultaneously, resolving the contradiction between easy replacement and safe retention.
Solution Approach 2:
Threaded holes act as intermediaries between the tile and the stator structure, providing a secure mechanical connection point that transcends the limitations of pure gravitational retention. The fastening bolts through these holes create a reliable anchor while maintaining the modular replacement capability.
2Reliability
If threaded bolts are used for fastening tiles, then safety is improved, but manufacturing complexity increases due to internal screw connection difficulties
Solution Approach 1:
Instead of threading the bolt from the inside of the stator where contamination makes it difficult, the threaded hole is inverted to be accessible from the outside. The fastening bolt passes through the tile and is secured from outside the stator, completely avoiding the contamination problem while maintaining secure fastening.
Solution Approach 2:
The fastening operation is extracted from the contaminated internal environment of the stator and moved to the external environment. The threaded hole serves as a conduit that allows the fastening mechanism to operate outside the contamination zone, resolving the manufacturing difficulty.
3Ease of manufacture
If cast metal tiles are used, then production cost is reduced, but manufacturing precision decreases requiring support strips
Solution Approach 1:
Support strips act as intermediaries between the cast tile base and the stator surface, compensating for the reduced manufacturing precision of cast tiles. These strips provide the necessary mechanical support and positioning accuracy that the cast base alone cannot guarantee, allowing cost-effective cast tiles to achieve the required precision through the intermediary support structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution significantly enhances safety and reduces maintenance downtime while keeping production costs low by allowing easy replacement of tiles and maintaining the effectiveness of the impact crusher.
Implementation Method 1
the outer jacket wall of the stator has bushings through which fastening bolts with threads that fit into the threaded hole of the tiles can be passed and can be secured from outside the stator
Implementation Method 2
The tiles, which are relatively heavy, are thus held in their position solely by gravity
Implementation Method 3
support strips and mats for enhanced stability and vibration damping
Data Source
Figure 1~2
Figure 3~6
AI summary
The aim of the invention is to propose a reliable, inexpensive option for the plates (10) that function as wear parts and are mounted on the inner face (3) of the casing wall of a stator (1). To achieve this aim, the plates are designed as cast parts and are fixed to the inner face (3) of the casing wall from the exterior (2) of the stator (1). The plates are fixed by means of fixing bolts (20), which are screwed into the plates (10) through the casing wall (2) from the exterior. The plates (10) have transverse threaded bores (18) that correspond to the bolts. Respective spacer rings (24) are pushed onto the fixing bolts (20) and the latter (20) are secured by wedge-shaped cotters (25) in both a positive and non-positive fit, the wedge-shaped cotter (25) pressing on the spacer rings (24) that lie against the outer face (4) of the casing wall (2). The inventive option is extremely economical and improves the operational safety in comparison to known options.